1.1 Mechanical Processes - Machining
uses electrical discharges (sparks) to erode material from conductive workpieces.
How does Electro-Discharge Machining (EDM) remove material from a workpiece?
_ _ _ uses a consumable wire; _ _ _ uses a tungsten electrode.
What is the difference between MIG and TIG welding?
A manufacturing process in which a heated metal is compressed between two dies using a mechanical press or power hammer.
What is drop forging?
Cables are flat for compact wiring.
What are ribbon cables?
Components attach to the board surface
What is surface mount components?
_ _ _ _ _ _ uses abrasive stones; _ _ _ _ _ _ _ uses a loose abrasive slurry.
What is the main difference between honing and lapping?
_ _ _ _ _ _ cutting uses ionized gas for faster, cleaner cuts.
How does plasma cutting differ from oxy-acetylene cutting?
_ _ _ _-die forging shapes metal freely, while _ _ _ _ _ _-die uses shaped moulds.
What is the difference between open-die and closed-die forging?
_ _ _ _ _ _ _ has a shielded design for signal integrity
What is a coaxial cable?
Solder multiple components simultaneously with a wave of solder
What is wave soldering?
It allows the creation of internal threads for fasteners, ensuring secure assembly.
Why is thread cutting using taps essential in metal fabrication?
Using _ _ _ _ _ _ _ _ _ reduces weight and improved sealing than fasteners
What is the purpose of using adhesives instead of mechanical fasteners?
Used in large bolts, shaft and axle manufacturing.
What applications for upset forging?
_ _ _ _ - _ _ _ _ by soldering or using crimp connectors.
How is a twin-lead cable terminated?
Soldering method preferred in surface-mount technology.
What is reflow soldering?
_ _ _ removes material using controlled anodic dissolution instead of mechanical force.
How does ECM differ from conventional machining techniques?
Steel, aluminum, and stainless steel cut with _ _ _ _ _ _
What materials are commonly cut using plasma cutting?
It refines grain structure, enhancing strength and durability.
How does forging alter the grain structure of metal?
Using laminated cores and copper windings.
How are large transformers constructed?
It speeds up production and ensures accuracy of placed components.
How does automatic pick-and-place technology improve PCB manufacturing?
Use protective eyewear, secure the workpiece to drill table, and ensure guards in place.
What safety precautions should be taken when performing hole production processes?
They influence edge quality, residual stress, and structural integrity
How do cutting techniques impact material properties?
Use heat-resistant gloves, proper ventilation, ear protection and controlled hammering techniques.
What safety precautions are necessary in a forging operation?
Copper or aluminium for their conductivity and efficiency.
What materials are used in motor winding, and why?
Protection of electronic components against moisture, dust, and mechanical stress. Not conformal coating.
What is potting?